HS2 to pioneer 3D printed graphene reinforced concrete

Aaron Morby 2 months ago
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HS2 London tunnels contractor Skanska Costain Strabag JV is to pioneer the use on-site of 3D reinforced concrete printing.

First structures printed will be part of Euston retaining walls and materials stores
First structures printed will be part of Euston retaining walls and materials stores

First proof of concept trials will begin in the spring using 5 tonne computer-operated robots. These will initially be used to build part of the retaining walls for the mainline out of Euston station as well as materials stores on the project.

The cutting-edge technology, called ‘Printfrastructure’, promises to bring big environmental benefits and cost savings, if deployed more widely.

Reinforced concrete structures will be printed with internal lattice strengthening, significantly reducing the quantity of concrete required as well as cutting waste.

Concreting robots have a 3m by 3m sweep and follow a pre-set programme.

In a further big advance, steel reinforcement will be replaced by microscopic strands of graphene only several atoms thick running through it like stripes in a stick of rock.

Replacing rebar should help to improved site safety, offer greater construction flexibility and shorter build time.

By removing steel and simplifying the construction process, which will no longer require cranes and fewer delivery trucks, the carbon reduction could be significant.

SCS JV estimates that the process it is developing with the Midlands firm ChangeMaker 3D and materials specialist Versarien will reduce concrete used and contribute toward reducing carbon by up to 50%.

If trials are successful, 3D printing could be used for multiple structures including bridge parapets, staircases, walls, columns and station platform segments.

HS2 innovation manager Rob Cairns said: “The project SCS JV and ChangeMaker 3D are collaborating on is a fantastic demonstration of the kind of far-reaching innovations HS2 enables.

“With a build programme spanning the decade and across the country, the project is creating an ideal environment to develop technologies with the potential to transform how major infrastructure is built.”

SCS JV Temporary Works Manager, Andrew Duck, said: ”Automation enabled by Printfrastructure’s 3D reinforced concrete printing creates a factory-like environmental that delivers a high-quality product that both increases efficient use of materials, and reduces our carbon footprint.

“It is important that we give technologies such as Printfrastructure the opportunity to flourish because of the possibilities it offers the industry to make a step change in how projects are delivered.”

 

 

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